GENERATING THREAD STITCH COLORING DATA FOR AN IN-LINE THREAD COLORING PROCESS
20260085459 ยท 2026-03-26
Inventors
Cpc classification
D05B67/00
TEXTILES; PAPER
International classification
Abstract
A computer-implemented method for generating thread stitch coloring data for an in-line thread coloring process, comprising: obtaining first thread stitch coloring data based on a digital representation that is to be produced as a decorative thread pattern; obtaining at least one thread color boundary defining a color change from a first color to a second color; determining residual stitch data based on the at least one thread color boundary being indicative of a number of residual stitches required in order to carry out said color change in an in-line thread coloring process; and generating second thread stitch coloring data based on the residual stitch data such that the color change of the first thread stitch coloring data is accounted for in the in-line thread coloring process.
Claims
1. A computer-implemented method for generating thread stitch coloring data for an in-line thread coloring process, comprising: obtaining first thread stitch coloring data based on a digital representation that is to be produced as a decorative thread pattern, the first thread stitch coloring data having a set of color representations assigned to a corresponding set of thread source representations; obtaining at least one thread color boundary from the first thread stitch coloring data, each thread color boundary defining a color change from a first color to a second color among said set of color representations; determining residual stitch data based on the at least one thread color boundary, the residual stitch data 6 being indicative of a number of residual stitches required in order to carry out said color change in an in-line thread coloring process; and generating second thread stitch coloring data based on the residual stitch data such that the color change of the first thread stitch coloring data is accounted for in the in-line thread coloring process, the second thread stitch coloring data having a set of color representations assigned to a single thread source representation.
2. The method of claim 1, wherein the residual stitch data is determined by estimating a number of residual stitches adapted to be carried out on a residual substrate Kay different from a substrate where the decorative thread pattern is to be produced.
3. The method of claim 2, wherein the substrate is adapted to be received by a main frame and the residual substrate is adapted to be received by at least one sub-frame.
4. The method of claim 1, wherein the residual stitch data is determined by estimating a number of residual stitches adapted to be carried out as underlay stitches on a substrate where the decorative thread pattern is to be produced.
5. The method (200) of claim 2, wherein the estimation of the number of residual stitches depends on one or more operating conditions of the in-line thread coloring process.
6. The method of claim 1, wherein determining the residual stitch data comprises defining a thread color boundary range indicating a range of residual stitches having intermediary colors between the first color and the second color, the thread color boundary range having a starting value being indicative of an initiation of the color change, and an end value being indicative of a completion of the color change.
7. The method of claim 6, further comprising setting a respective buffer to each one of the starting value and the end value, the buffers indicating additional number of stitches to the residual stitch data on a respective end of the thread color boundary range.
8. The method of claim 6, wherein the thread color boundary range is dependent on one or more of a number of stitches, an amount of consumed thread, a substrate property, a thread property, and a combination thereof.
9. The method of claim 1, wherein said color change is caused by one or more of a color transition in the digital representation, a cutting process of a thread, a relative movement of a substrate, and a combination thereof.
10. The method of claim 1, wherein the residual stitch data comprises information of one or more of a length of the color change, a direction of residual stitches used in carrying out said color change, a substrate property where the color change is to be carried out, a thread property of a thread to be used for carrying out the color change, and a combination thereof.
11. The method of claim 1, wherein a subsequent consumption of a thread source in said in-line thread coloring process comprises, based on the second thread stitch coloring data, causing control of the in-line thread coloring process by: controlling an in-line thread coloring process of a thread; controlling a thread consumption process of the thread with respect to a substrate; and controlling a residual embroidery process of the thread as one or both of residual stitches onto a residual substrate different from the substrate, and residual stitches as underlay stitches onto the substrate.
12. The method of claim 1, wherein generating the second thread stitch coloring data comprises: obtaining pattern data from the digital representation, the pattern data comprising a plurality of pixels, each pixel being associated with a position in the digital representation and a color value; generating resolution data by processing the pattern data, wherein processing the pattern data comprises determining a thread arrangement comprising a plurality of stitches, wherein the thread arrangement corresponds to a digital representation to be produced in the in-line thread coloring process; and generating the second thread stitch coloring data for the thread at least based on said resolution data.
13. The method of claim 12, wherein processing the pattern data further comprises determining information relating to a length of the stitches, a direction of the stitches and a type of connection used to connect one or more stitches to each other.
14. A control unit comprising a processor configured to carry out the steps of the method of claim 1.
15. A system for in-line treatment of at least one thread for use with a thread consuming device, the system comprising: a treatment unit comprising at least one discharge device comprising at least one nozzle, arranged along the at least one thread, being configured to dispense one or more coating substances onto the at least one thread when activated; and a control unit configured to control the discharge device to dispense the coating substances onto the at least one thread based on the second thread stitch coloring data generated from the method of claim 1.
16. A non-transitory computer-readable storage medium comprising instructions, which when executed by one or more processors of a control unit, cause the processors to: obtain first thread stitch coloring data based on a digital representation that is to be produced as a decorative thread pattern, the first thread stitch coloring da a having a set of color representations assigned to a corresponding set of thread source representations; obtain at least one thread color boundary from the first thread stitch coloring data, each thread color boundary defining a color change from a first color to a second color among said set of color representations; determine residual stitch data based on the at least one thread color boundary, the residual stitch data being indicative of a amber of residual stitches required in order to carry out said color change in an in-line thread coloring process; and generate second thread stitch coloring data based on the residual stitch data such that the color change of the first thread stitch coloring data is accounted for in the in-line thread coloring process, the second thread stitch coloring data having a set of color representations assigned to a single thread source representation.
17. A computer program product comprising computer code for performing functionality of the method (200) of claim 1.
18. The method of claim 1, further comprising: dispensing, by at least one nozzle arranged along the at least one thread, one or more coating substances based on the second thread stitch coloring data.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] Examples of the disclosure will be described in the following description; reference being made to the appended drawings which illustrate non-limiting examples of how the inventive concept can be reduced into practice.
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DETAILED DESCRIPTION
[0046]
[0047] The treatment unit 100 allows the embroidery machine 15 to operate without the provision of uniquely pre-colored threads, as is required for conventional thread consuming devices. Instead, the treatment unit 100 provides in-line coloring of a thread in accordance with predetermined coloring patterns, such that a colored embroidery can be produced. The treatment unit 100 thus replaces individual thread reels each having a pre-colored thread, as is present in traditional systems of the prior art of consuming a thread.
[0048]
[0049] The substrate 3 is preferably a textile, fabric or cloth. In some examples, the substrate 3 has a fixed set of properties, for example a specific thickness or elasticity constant. The substrate 3 may be divided into different sections where each section may have different properties relating to for example the thickness and/or elasticity of the substrate 3.
[0050]
[0051] The thread guiding device 140, which may e.g., be in the form of one or more guiding rollers 142, 144 or other suitable means, is ensuring that the thread 20 is aligned with one or more treatment nozzles forming part of discharge device 150.
[0052] The discharge device 150 is configured to discharge treatment substance, such as a coloring substance, onto the thread 20 as it passes the discharge device 150. For this the nozzles are preferably arranged in the longitudinal direction of the thread 20. The discharge device 150 may be moveable by means of a drive unit (not shown). Having a drive unit will make it possible to arrange the discharge device 150 in different operating states in order to perform different tasks, such as for example a first state of dispensing a coating substance to a thread and a second state of performing a cleaning session, or other maintenance or idling. For this a drive unit may be connected to the discharge device 150. The drive unit may be configured to move the discharge device 150 between an idle position and an operational position by means of a transmission having different transmission ratios during the motion from the idle position towards the operational position.
[0053] Downstream the discharge device 150 another thread guiding device 160 may be provided. The second thread guiding device 160 is cooperating with the first thread guiding device 140 such that the position of the thread 20 is correct during its travel along the discharge device 150. The second thread guiding device 160 may e.g., be in the form of one or more guiding rollers 162, 164, although it may also be designed to induce a rotation of the thread 20 along its longitudinal axis.
[0054] The treatment unit 100 may further comprise a thread speed sensor (not shown) configured to measure the speed of the thread 20 passing through the treatment 10. The thread speed sensor may be arranged outside or within the housing 105. The thread speed sensor may be arranged just before the discharge device 150. The thread speed sensor may in some examples replace or complement the thread guiding device 140. In some examples, the thread speed sensor may be arranged just after the discharge device 150. The thread speed sensor may in some examples replace or complement the second thread guiding device 160. In yet some examples, two thread sensors are provided, the first arranged before the discharge device 150 and the second arranged after the discharge device 150, e.g., as the first and second thread guiding devices 140, 150.
[0055] The thread 20 is then fed forward to pass one or more fixation units 170 which are provided in order to fixate the treatment substance to the thread 20. The fixation unit 170 preferably comprises heating means, such as a hot air supply or heated elements, or an UV light source such that the treatment substance, e.g., a coloring substance, is cured or fixated onto the thread 20. The fixation unit 170 may either be arranged horizontally, vertically, or at an angle between horizontally and vertically.
[0056] Before exiting the housing 105 the thread 20 can pass a cleaning unit 180, such as an ultrasonic bath, where unwanted particles are removed from the thread 20. As the treatment substance is fixated onto the thread 20, the cleaning unit 180 will leave the treatment substance unaffected.
[0057] The treatment unit 100 may further comprise a lubrication unit 185 arranged inside the housing 105. Additional thread buffers and feeders (not shown) may also be included in the treatment unit 100, arranged at various positions in the thread path.
[0058] The thread 20 preferably exits the treatment unit 100 through an aperture or similar, whereby the thread 20 is forwarded to an associated thread consuming device, such as the embroidery machine 15.
[0059] The thread feeder 130 and the other components engaging with the thread 20 during operation are preferably configured such that the force required to pull the thread 20 from the treatment unit 100, i.e. the pulling force applied by the downstream embroidery machine 15, is approximately the same as if the treatment unit 100 was replaced by prior art thread reels.
[0060] A control unit 109 with associated electronics, such as power electronics, communication modules, memories, etc., is also provided. The control unit 109 is connected to the thread feeder 130, the discharge device 150, and the fixation unit 170 for allowing control of the operation of these components. Further, the control unit 109 is configured to controlling operation of the entire treatment unit 100 including the cleaning unit 180, the lubrication unit 185, a disruption of the thread 20, the thread speed at various position along the treatment unit 100, the thread buffers, etc. The control unit 109 may also be configured to receive control signals from one or more components of the treatment unit 100, e.g., control signals for triggering specific control, or other information relating to e.g., thread consumption by the embroidery machine 15. The control unit 109 is also configured to receive information from a second control unit 110, as soon will be described more in detail.
[0061] The control unit 109 may comprise one or more processors configured to be implemented by any commercially available CPU (Central Processing Unit), DSP (digital signal processor) or any other electronic programmable logic device, or a combination of such processors or other electronic programmable logic device. The control unit 109 may be implemented using instructions that enable hardware functionality, for example, by using executable computer program instructions in a general-purpose or special-purpose processor that may be stored on a computer readable storage medium (disk, memory, etc.) to be executed by such a processor.
[0062] In some examples, a user interface is also provided, preferably via a display 195 arranged at the front end of the housing 105. The display 195 allows a user to interact with the control unit 109 and is thus connected thereto, so that the control parameters of the thread feeder 130, the discharge device 150, the fixation unit 170, etc. may be set depending on process specifications. The display 195 may also be used for alerting the user of critical situations, whereby the display 195 may be used for the control unit 109 to issue alarms or the like.
[0063] The control unit 109 may be configured to receive digital content. Digital content may be a photography captured by a camera unit, included in or provided external to the system 300. The digital content may alternatively be virtually rendered by the control unit or some other type of device capable of rendering digital content.
[0064] The control unit 109 may be configured to communicate in any known short-range or long-range communication standards known in the art via a communication interface. Short-range communication interfaces include, for instance, IEEE 802.11, IEEE 802.15, ZigBee, WirelessHART, WiFi, Bluetooth, BLE, RFID, QR, WLAN, MQTT IoT, CoAP, DDS, NFC, AMQP, LoRaWAN, Z-Wave, Sigfox, Thread, EnOcean, mesh communication, or any other form of proximity-based device-to-device radio communication signal such as LTE Direct. Long-range communication interfaces include, for instance, W-CDMA/HSPA, GSM, UTRAN or LTE.
[0065] A memory unit (not shown) may be associated with the control unit 109, for instance reside therein, and implemented in any known memory technology, including but not limited to E(E)PROM, S(D)RAM or flash memory. The memory unit may alternatively be a cloud storage unit. The cloud storage unit may be deployed as a SQL data model such as MySQL, PostgreSQL or Oracle RDBMS. Alternatively, deployments based on NoSQL data models such as MongoDB, Amazon DynamoDB, Hadoop or Apache Cassandra may be used. Alternatively, the memory unit may reside in an external server configured in any type of client-server or peer-to-peer (P2P) computer architectures. Server configurations may, for instance, involve any combination of e.g., web servers, database servers, email servers, web proxy servers, DNS servers, FTP servers, file servers, DHCP servers, to name a few.
[0066] In some examples, the memory unit may be integrated with or internal to the control unit. The memory unit may store program instructions for execution by the control unit, as well as temporary and permanent data used by the control unit. Program instructions and/or temporary and permanent data pertain to the in-line thread stitch coloring data as well as other data used by the control unit to generate said in-line thread stitch coloring data. The stored in-line thread stitch coloring data may be used for coloring a thread either directly (with at least some expected delay as is readily understood by the person skilled in the arts of computer networking), or at a later stage.
[0067] It should be noted that the components described above may not necessarily be included in the stand-alone treatment unit 100. In other examples the components of the treatment unit 100 are separated into several units, where at least one unit thereof is a stand-alone unit. Preferably, the stand-alone unit at least includes the at least one discharge device 150.
[0068] The control unit 109 could be part of the system 10, the treatment unit 100, the thread consuming device 15 or be an external control unit.
[0069] As illustrated in
[0070]
[0071] The treatment unit 100 comprises one or more discharge devices 150. Each discharge device 150 is preferably formed as a series of ink-jet print heads 151a-d, each print head 151a-d having one or more nozzle arrays. Each nozzle array typically comprises hundreds or thousands of nozzles. For illustrative purpose only six nozzles 152a-f are shown for one print head 151a-d; it should however be realized that each nozzle array may be provided with hundreds or thousands of nozzles 152 each. As an example, each print head 151a-d may be associated with a single color; in the shown example, the discharge device 150 has four print heads 151a-d, each print head 151a-d being associated with a specific color according to the CMYK standard. However, other coloring models may be used as well.
[0072] The exact configuration of the discharge device 150 arranged in the treatment unit 100 may vary. For example, the treatment unit 100 may be provided with a single discharge device 150 having a plurality of print heads 151a-d. Each print head 151a-d may in turn be provided with a plurality of nozzles 152a-f.
[0073] In some examples the treatment unit 100 is provided with several discharge devices 150, arranged either in series or in parallel. Each discharge device 150 is then provided with a plurality of print heads 151a-d. If serially arranged, the upstream discharge device 150 may have print heads 151a-d being associated with one or more colors of a specific color standard, while the downstream discharge device 150 has print heads 151a-d being associated with other colors of the same color standard. If arranged in parallel, each discharge device 150 may have print heads 151a-d being associated with all colors of a specific color standard, but with different threads 20. For such examples, two separate threads 20 can be treated simultaneously and in parallel. Combinations of parallel/serial configurations are of course also possible.
[0074] In a yet some examples, the discharge device 150 is only having a single print head 151a-d. Dynamic coloring of the thread 20 would then require several discharge devices 150 of the treatment unit 100.
[0075] Each nozzle 152a-f may dispense a coating substance having a color according to the CMYK color model, where the primary colors are Cyan, Magenta, Yellow, and Black. It may thus be possible to dispense a wide variety of colors onto the thread by activating nozzles 152a-f such that the total coloring substance of a specific length of the thread 20 will be a mix of the coloring substances dispensed by the nozzles 152a-f. As explained earlier, this is preferably achieved by having several print heads 151a-d arranged in series, whereby the nozzles 152a-f of a specific print head 151a-d are dedicated to a single color. In some examples, each nozzle 152a-f-f dispenses a coating substance having a color comprising a mix of two or more primary colors of the CMYK color model. It should be noted that the nozzles could be arranged to dispense different kinds of coating substances, not only color coatings.
[0076] The control unit 109 is configured to control the activation of the nozzles 152a-f such as the coating substance is emitted onto the thread 20 as it passes through the treatment unit 100, and especially pass the discharge device 150. By such configuration very precise coloring of the thread 20 is possible e.g., in order to provide advanced embroidery patterns, visually extremely sophisticated by means of the coloring provided by the treatment unit 100. For a coloring operation the control unit 109 receives one or more input signals specifying the desired color and/or coloring effect. The color input preferably includes information regarding the exact color, as well as the longitudinal start and stop positions of the thread 20 for that particular color. The longitudinal start and stop position could be represented by specific time values if the thread speed is determined.
[0077] The coloring operation may generate different visual effects on the thread. Visual effects may e.g., include a gradient, stripes, mottling, etc. More specifically, typical effects which are used include i) color change in respect to absolute thread length (such as 3 cm red, 23 cm green), ii) color change in respect to relative thread length (such as 30% red, 70% green), iii) solid color, iv) gradient, v) noise, vi) manipulation (such as change in hue, tone, brightness, contrast, etc.), vii) mix (i.e. merging of different swatches). Each one of these effects can be repeated for a number of times within the area of the certain effect. Within this context, the term noise relates to one or more colors to which some kind of manipulation is added, e.g., saturation or brightness, where the manipulation is a fractal, Gaussian, or other. The term swatch relates to a setting that will generate a specific dispensing pattern, of the coating substance, for a certain design segment. The design segment may be a part of a pattern, figure, shape, text, emblem, symbol, color gradient, or the like. A swatch may e.g., be a solid, a gradient, or a transformation from a solid which after a certain length transforms to a gradient between two colors.
[0078] With further reference to the example of
[0079] The thread portions may be a stich. In this context, a stitch may for example be a single turn of thread, a single loop of thread, a single turn of yarn or a single loop of yarn. Stitches may for example be applied using sewing, knitting, embroidery, crochet and/or needle lace-making.
[0080] Depending on particular details of the thread consuming device 15, the thread arrangement may be a stitch pattern (such as in the case of an embroidery machine, a knitting machine, or a sewing machine), a weave pattern (such as in the case of a weaving machine), or a tuft pattern (such as in the case of a tufting machine).
[0081] In embroidery, a stitch can for example be seen as a running stitch that pass through the fabric in a simple up and down motion, a back stitch that pass through the fabric in an encircling motion, a chain stitch that catch a loop of the thread on the surface of the fabric, a knotted stitch that is formed by wrapping the thread around the needle. A stitch may be formed by generating two insertion points into the substrate 30.
[0082] In knitting, a stitch can be seen as single loop of yarn, secured to the loops beside it to form a row or course of stitches and to the loops above and below it to form a wale. In securing the previous stitch in a wale, the next stitch can pass through the previous loop either from below or above. In crochet, a stitch can be seen as being made by pulling a loop of thread through the previous stitches. Although specific types of stitches have been mentioned, it should be noted that all kinds of stitches can be used for the system disclosed herein.
[0083]
[0084] In the following examples of the present disclosure, the thread portions may therefore be stitches, and the residual stiches may be one or more of 1) stitches on a residual fabric, or 2) underlay stitches. The residual fabric is not intended to be produced with a decorative thread pattern that is part of the finished product. The fabric can be seen as a residual fabric, a waste fabric or the like. The fabric is configured to receive at least one unwanted or residual stich that accounts for the color change. Accordingly, it is possible to control the color change of the thread on a substrate that is not to be part of the finished product. Concerning residual stitches being envisaged as underlay stitches, these are arranged on an opposite side of the decorative pattern being produced such that they are not visually distinguishable by a person looking at said decorative pattern from his point of view. To this end, the underlay stitches are not necessarily arranged at an opposing side of the substrate from the side where the decorative pattern is produced, per se, but rather an opposing side of the decorative pattern itself.
[0085]
[0086] The first thread stitch coloring data 114 comprises a set of color representations 114a and a corresponding set of thread source representations 114b. In non-in-line processes one color is typically associated with a respective thread source. Therefore, in the representations thereof a particular color representation 114a is assigned to a particular thread source representation 114b, thus forming a 1-1 relationship. Any suitable data structure may be used for storing said assignment of color representations to thread source representations, such as a hash map, array, tuple, set, graph, and the like.
[0087] The control unit 110 is configured to obtain the first thread stitch coloring data 114. The first thread stitch coloring data 114 may be obtained from a user interface, such as the display 195 explained with reference to
[0088] The control unit 110 is configured to obtain at least one thread color boundary 115 from the first thread stitch coloring data 114. The thread color boundary defines a color change from a first color to a second color among the set of color representations 114a. By way of obtaining the thread color boundary from the first thread stitch coloring data 114, the control unit 110 may recognize where one or more color transitions take place in the digital representation. Generally, color changes may be a result of one or more of a color transition in the digital representation which the first thread stitch coloring data is based on, a cutting process of a thread, a relative movement of a substrate, and a combination thereof.
[0089] Recognizing where said one or more color transitions take place may involve, by the control unit 110, obtaining pattern data from the first thread stitch coloring data 114. Pattern data comprises information related to pixels in the digital representation. Accordingly, the pattern data comprises a plurality of pixels, wherein each pixel is associated with a position in the digital image and a color value. In the example where the digital representation is a digital image, the pattern data may be seen as the image data. Since the digital representation is typically two-dimensional, the position is indicative of a two-dimensional position. As an example, a pixel located at a top left corner of the digital image may have a position 0, 0, and a pixel located at the bottom right corner of the digital image may have a position row.sub.max, col.sub.max, wherein row.sub.max is the maximum number of pixel rows in the digital image and col.sub.max is the maximum number of pixel columns in the digital image. In this example, if the resolution of the digital representation is 1080p (19201080), the pixel located at the bottom right corner of the digital image has the position 1080, 1920. Similar pixel positions can be realized for other image resolutions, e.g., 2K, 4K, 8K and so forth.
[0090] The color value may pertain to any color space known in the art, e.g., the RGB or CMYK color space. Accordingly, if the color value of a pixel in the RGB color space is derived as 0, 0, 0, the color value represents the color black.
[0091] After having obtained the pattern data of the first thread stitch coloring data, the method further involves generating resolution data. Resolution data is generated by processing the pattern data of the digital representation. During this procedure, information relating to a thread arrangement comprising a plurality of consecutive thread portions of the pattern to be created/produced is determined. The processing of the pattern data may comprise determining information relating to the length of the thread portions, the direction of the thread portions, and/or the type of connections used for consecutive thread portions.
[0092] The control unit 110 is further configured to determine residual stitch data 116 based on the (at least one) thread color boundary 115. The residual stitch data indicates a number of residual stitches required in order to carry out the color change in an in-line thread coloring process. The residual stitch data may be determined differently depending on how the residual stitches are to be carried out in a future in-line thread coloring process, as will be discussed later on in this disclosure.
[0093] The residual stitch data may comprise information of one or more of a length of a color change, a direction of residual stitches used in carrying out said color change, a substrate property where the color change is to be carried out, a thread property of a thread to be used for carrying out the color change, and a combination thereof. The residual stitch data may comprise information relating to a type of residual stitch to be used. The type of residual stitch relate to whether underlay stitches or residual stitches are to be used. This information may be determined automatically by the control unit 110, for instance based on the other data of the residual stitch data. For instance, if the residual stitch data indicate that a length of a color change is 5 cm, a direction of residual stitches is in the longitudinal direction of the substrate, the substrate is of a particular material, e.g., linen, and a certain thread is used, e.g., polyester fibres, the control unit 110 may be configured to, based on this information, automatically set a type of residual stitch to underlay stitches or the residual stitches on a residual substrate. This selection may thus depend on respective suitability of the different type of information of the residual stitch data. In alternative examples the type of residual stitch may be selected by a user.
[0094] The control unit 110 is configured to generate the second thread stitch coloring data 117 based on the residual stitch data 116 such that the color change of the first thread stitch coloring data 114 is accounted for in the in-line thread coloring process. In contexts of the present disclosure, the term accounted for typically corresponds to a future usage of the second thread stitch coloring data 117 requiring additional stitches compared to a usage of the first thread stitch coloring data 114. This is due to the fact that a color change in an in-line process is not as intuitive as the corresponding color change in a non-in-line process. In in-line processes, there is typically some intermediary colors in between the first and the second colors due to the (re)coloring of the thread from the first to the second color. Conversely, in non-in-line processes the color change would happen immediately as a response to a switch between a first thread source to a second thread source, the respective thread sources storing thread of different colors. Such switches are typically carried out by cutting the thread exactly at the position where the thread color boundary is due. This is, however, not possible for in-line processes as there is inevitably envisaged one or more additional stitches to account for the (re)coloring of the thread. In addition, for in-line processes, it can sometimes be difficult to predict exactly where the thread color boundary is due.
[0095] In view of the above, the second thread stitch coloring data 117 is adapted to be processed by a system for in-line thread coloring, such as the system 10 previously described. The conversion may be carried out in the same system as the system obtaining the first thread stitch coloring data 114, or another system. It is thus envisaged that the second thread stitch coloring data 117 may be received by another system for subsequent production of the decorative pattern. It is also envisaged that the second thread stitch coloring data 117 may be consumed by the same system after it has been generated based on the first thread stitch coloring data. This is thanks to the second thread stitch coloring data 117 being packaged in a file suitable to be transmitted to other in-line thread coloring systems.
[0096] The first and second thread stitch coloring data 114, 117 may be managed in a corresponding file, such as an embroidery file. Since the embroidery file includes information pertaining to a digital representation that is to be produced as a decorative thread pattern, the embroidery file may be managed in a bitmap graphics format including but not being limited to GIF, JPEG, PNG, TIFF, XBM, BMP, PCX, and the like. The digital representation may alternatively be virtually rendered by the control unit or some other type of device capable of rendering digital content.
[0097] In following examples of the disclosure, various ways of determining the residual stitch data will be defined. Although these examples refer to physical components such as a frame, it shall be understood that the determination of the residual stitch data is carried out by the control unit 110 before the actual decorative pattern has been produced. The illustrative drawings are merely provided for explanatory purposes, and shall be understood to convey the meaning of what is to occur once the second thread stitch coloring data is used in an in-line thread coloring process, based on previously determined residual stitch data adhering to the thread color boundary obtained from the first thread stitch coloring data.
[0098]
[0099] In order to allow for visual effects of the decorative thread pattern to be produced, the control unit 110 is configured to determine an object to be produced as a decorative thread pattern. From this object, which e.g., may be a graphical representation of an item, an image, a logotype, etc., the control unit 110 is further configured to determine a thread arrangement comprising a plurality of consecutive thread portions, each thread portion having a thread portion direction, wherein the entire thread arrangement corresponds to said object to be produced. The control unit 110 may be configured to receive thread arrangement data from another control unit. For instance, the thread consuming device 15 may be provided by a first supplier, while the treatment unit 100 is provided by a second supplier. In such case the control unit 110 may be provided with the treatment unit 100, while being configured to receive thread arrangement data from a control unit 110 of the thread consuming device 15.
[0100] In these examples a frame 30 is employed. The frame 30 is arranged to hold a substrate 3 having two sections 3a, 3b. In these examples the substrate 3 is a fabric 3. The embroidery frame 30 comprises a main frame 32 and at least one sub-frame 34. The main frame 32 is configured to receive the fabric 3a that is to be produced with a decorative thread pattern. The sub-frame 34 is configured to receive a fabric 3b that is not intended to be produced with a decorative thread pattern, i.e., the residual fabric 3b. The embroidery frame 30 comprises four sides 31a-d, two longitudinal sides 31a, 31b and two transverse sides 31c, 31d. The longitudinal sides are of a length H3 and the transverse sides are of a length L3. The sub-frame 34 is preferably smaller in size than the main frame 32. This is preferred as the main frame 32 is the frame configured to hold the fabric 3a that is to be produced with a decorative thread pattern.
[0101] In the example of
[0102] In the example of
[0103] In the example of
[0104] In the example of
[0105] The relationships between the dimensions of the sub-frame 34 and the main frame 32 may be altered. Hence, the frame 30 has a fixed dimension, whereas the dimensions of the sub-frame 34 and the main frame 32 are adaptable. This adaptation in size could for example be realized by making the main frame and the sub-frame slidable in relation to each other. Alternatively, the main frame 32 and the sub-frame 34 have fixed dimensions.
[0106] As previously stated, the frame 30 may be arranged on a movable stage 2b. The frame 30 can thus be moved in relation to the at least one needle of the thread consuming device 15. The movement of the movable stage 2b may be performed based on instructions from the thread consuming device 15, the treatment unit 100 and/or from a control unit 110.
[0107]
[0108] The stitching order is in this example determined to start with a first color c1 corresponding to the color of the head of the parakeet, proceed to a second color c2 corresponding to the color of the wings of the parakeet, proceed to a third color c3 corresponding to the color of the body of the parakeet, and finish with a fourth color c4 corresponding to the color of the feet of the parakeet. The residual stitch data has been determined by identifying three color changes: c1 to c2, c2 to c3, and c3 to c4. For each color change, a number of residual stitches have been estimated. To this end, the parakeet will be produced according to the following steps: (i) coloring the thread with the first color c1 and stitching the head of the parakeet on the substrate 3a using said thread colored with the first color c1; (ii) identifying an upcoming color switch, thereby initiating residual stitching on the residual substrate 3b at a first stitch patch using the thread colored with the first color c1 while initiating (re)coloring of the thread into the second color c2; (iii) identifying that the color switch is completed, thereby initiating stitching of the wings of the parakeet on the substrate 3a using said thread colored with the second color c2; (iv) identifying an upcoming color switch, thereby initiating residual stitching on the residual substrate 3b at a second stitch patch using the thread colored with the second color c2 while initiating (re)coloring of the thread into the third color c3; (v) identifying that the color switch is completed, thereby initiating stitching of the body of the parakeet on the substrate 3a using said thread colored with the third color c3; (vi) identifying an upcoming color switch, thereby initiating residual stitching on the residual substrate 3b at a third stitch patch using the thread colored with the third color c3 while initiating (re)coloring of the thread into the fourth color c4; and (vii) identifying that the color switch is completed, thereby finalizing stitching of the parakeet by stitching the feet thereof on the substrate 3a using said thread colored with the fourth color c4.
[0109] In the example above and in other examples where identification of color switches are carried out, various different methods known in the art may be employed for these purposes. For instance, color identification may be carried out using an illuminator device configured to illuminate an area where the thread is located, and an image sensor, such as a camera, configured to capture an image of the illuminated thread. Thereafter, one or more image processing techniques may be employed using e.g., color analysis or color segmentation for determining color data of the thread. The color data may be compared to expected color data, thereby outputting a determination whether a color change has been carried out or not. The illuminator device and image sensor may be arranged at a suitable location in the system 10, and the control unit 110 may be configured to control the operations thereof, as well as perform suitable image processing techniques.
[0110]
[0111]
[0112]
[0113] Regardless of what method is used for estimating the number of residual stitches, said estimation may depend on one or more operating conditions of the in-line thread coloring process. Said operating conditions may pertain to the device where the in-line thread coloring takes place, the substrate used, the thread used, and/or external conditions. Alternatively, the number of residual stitches may be set to a fixed stitch value, such as 10 stitches, or a fixed thread length value, such as 20 cm, or practically any type of other appropriate fixed value.
[0114]
[0115] The first thread color boundary range r1 has a starting value s1 and an end value e1. For the second, third and fourth thread color boundary ranges r2, r3, r4, various buffers are defined. The purpose of adding buffers to the ranges is to provide additional assurance that the entire color change has been completed before returning to stitching the decorative thread pattern. The size of the buffers may vary. The number of buffers may vary. Buffers may be assigned to the starting value and/or to the end value of a thread color boundary range. Typically, a buffer added to a starting value will be associated with the first color, while a buffer added to an end value will be associated with the second color, and the range therebetween some type of combination thereof with intermediary colors between the first and second colors. Similar to the thread color boundary range, the buffers may be automatically determined by the control unit 110 based on operating conditions of the in-line thread coloring process. Moreover, the buffers may be altered during operation of the in-line thread coloring process. In addition, the buffers may be selected by an operator.
[0116] The second thread color boundary range r2 has a starting value s2 and an end value e2. Further, two buffers b1-1, b1-2 are defined, one for each one of the starting and end values s2, e2. The third thread color boundary range r3 has a starting value s3 and an end value e3. Further, one buffer b2-1 is defined for the starting value s3. The fourth thread color boundary range r4 has a starting value s4 and an end value e4. Further, one buffer b3-2 is defined for the end value e4.
[0117]
[0118] The method 200 involves a step 210 of obtaining first thread stitch coloring data based on a digital representation that is to be produced as a decorative thread pattern, the first thread stitch coloring data having a set of color representations assigned to a corresponding set of thread source representations. The method 200 involves a step 220 of obtaining at least one thread color boundary from the first thread stitch coloring data, each thread color boundary defining a color change from a first color to a second color among said set of color representations. The method 200 involves a step 230 of determining residual stitch data based on the at least one thread color boundary, the residual stitch data being indicative of a number of residual stitches required in order to carry out said color change in an in-line thread coloring process. The method 200 involves a step 240 of generating second thread stitch coloring data based on the residual stitch data such that the color change of the first thread stitch coloring data is accounted for in the in-line thread coloring process, the second thread stitch coloring data having a set of color representations assigned to a single thread source representation.
[0119] The step 240 of generating the second thread stitch coloring data may involve a step 242 of obtaining pattern data from the digital representation, the pattern data comprising a plurality of pixels, each pixel being associated with a position in the digital representation and a color value. The step 240 may further involve a step 244 of generating resolution data by processing the pattern data, wherein processing the pattern data comprises determining a thread arrangement comprising a plurality of stitches, wherein the thread arrangement corresponds to a digital representation to be produced in the in-line thread coloring process. The step 240 may further involve a step 246 of generating the second thread stitch coloring data for the thread at least based on said resolution data.
[0120] The method 200 may further involve a subsequent consumption of a thread source in said in-line thread coloring process. This may be performed based on the second thread stitch coloring data and a caused control of the in-line thread coloring process by, at step 250, controlling an in-line thread coloring process of a thread, at step 252, controlling a thread consumption process of the thread with respect to a substrate, and at step 254, controlling a residual embroidery process of the thread. The residual embroidery process may be controlled as one or both of residual stitches onto a residual substrate different from the substrate, and residual stitches as underlay stitches onto the substrate.
[0121]
[0122] The control unit 109, 110 is further configured to cause 315 a relative movement between the needle of the thread consuming device and the sub-frame 34. In one embodiment, this is performed by causing the movable stage 2b to move the frame 30. In yet one embodiment, the control unit 109, 110 is configured to cause a movement of the needle of the thread consuming device 15.
[0123] Once the needle and the sub-frame 34 are in place relative each other, the control unit 109, 110 is further configured to cause 320 the thread consuming device to perform at least one residual stich on the residual fabric 3b.
[0124] Once the residual stich(es) are made into the fabric 3b, the control unit 109, 110 is configured to cause 325 the thread consuming device 15 to cut the at least one thread 20 used to perform the at least one residual stich.
[0125] The control unit 109, 110 is further configured to cause 330 a relative movement between the needle of the thread consuming device and the main frame 32. In one embodiment, this is performed by causing the movable stage 2b to move the frame 30. In yet one embodiment, the control unit 109, 110 is configured to cause a movement of the needle of the thread consuming device 15.
[0126] The method of cutting the thread is also applicable to underlay stiches.
[0127] Further alternative aspects of the present disclosure are described in the following examples.
[0128] An embroidery frame 30 to be used with a system for in-line treatment of a thread and a thread consuming device 15 is provided. The embroidery frame 30 comprises: a main frame 32 configured to receive a first portion of one or more substrates, wherein the first portion is to be produced with a decorative thread pattern, and at least one sub-frame configured to receive second portion of the one or more substrates, wherein the second portion is a residual substrate.
[0129] The sub-frame has a dimension smaller than the main frame 32. The dimensions of the main frame 32 and the at least one sub-frame may be adaptable in relation to each other.
[0130] The substrate of the sub-frame is configured to receive at least one unwanted/residual stich.
[0131] The at least one unwanted/residual stich is related to a color transition.
[0132] The embroidery frame 30 is configured to be arranged on a movable stage 2b so that the substrate in the embroidery frame 30 is movable in relation to the thread consuming device 15.
[0133] A control unit 109, 110 is configured to cause a relative movement between a needle of the thread consuming device 15 and the sub-frame, or cause a relative movement between a needle of the thread consuming device 15 and the main frame 32.
[0134] The control unit 109, 110 is further configured to: cause the thread consuming device 15 to perform at least one stich, with the at least one thread using the at least one needle, and the on the substrate 3a, that is to be produced with a decorative thread pattern, arranged in the main frame 32, cause the thread consuming device 15 to cut said at least one thread used to perform the at least one stich, cause a relative movement between a needle of the thread consuming device 15 and the sub-frame, cause the thread consuming device 15 to perform at least one residual stich on the residual substrate 3b, cause the thread consuming device 15 to cut said at least one thread used to perform the at least one residual stich, and cause a relative movement between a needle of the thread consuming device 15 and the main frame 32.
[0135] A system for in-line treatment of thread for use with a thread consuming device 15, comprising an embroidery frame 30 is provided. The system is in operative communication with a control unit 109, 110 being configured to: cause a relative movement between a needle of the thread consuming device 15 and the sub-frame, or cause a relative movement between a needle of the thread consuming device 15 and the main frame 32.
[0136] As should be understood by a person skilled in the art, different variations of these examples are covered by the inventive concept. For example, the treatment unit 100 may be arranged with one control unit 110a whereas the tread consuming device 15 only relies on the external control unit 110c. Moreover, the movable stage 2b may be arranged with a separate control unit although not shown.
[0137] Although the present disclosure has been described above with reference to specific examples, it is not intended to be limited to the specific form set forth herein. Rather, the disclosure is limited only by the accompanying clauses. As is understood by the skilled person, an example as defined herein may be interpreted as an embodiment of the disclosure.
[0138] The term comprises/comprising does not exclude the presence of other elements or steps. Additionally, although individual features may be included in different clauses, these may possibly advantageously be combined, and the inclusion in different clauses does not imply that a combination of features is not feasible and/or advantageous. In addition, singular references do not exclude a plurality. The terms a an, first, second etc., do not preclude a plurality. Reference signs in the clauses are provided merely as a clarifying example and shall not be construed as limiting the scope of the clauses in any way.